Maintenance systems for use in systems and methods for processing objects including mobile matrix carrier systems

ABSTRACT

A maintenance system is disclosed for assisting in maintaining an automated carrier system for moving objects to be processed. The maintenance system includes a plurality of automated carriers that are adapted to move on an array of discontinuous standard track sections, each said automated carrier including a carrier body that is no larger in either a length or width direction that a standard track section, and an automated maintenance carrier that is adapted to move on the array of discontinuous track sections, said automated maintenance system including a maintenance body that is larger in at least one of a length or width direction than the standard track section.

PRIORITY

The present application is a continuation of U.S. patent applicationSer. No. 16/172,339, filed Oct. 26, 2018, now U.S. Pat. No. 10,988,323,issued Apr. 27, 2021, which claims priority to each of U.S. ProvisionalPatent Application Ser. No. 62/578,030 filed Oct. 27, 2017, U.S.Provisional Patent Application Ser. No. 62/641,640 filed Mar. 12, 2018,and U.S. Provisional Patent Application Ser. No. 62/681,409 filed Jun.6, 2018, the disclosures of all of which are hereby incorporated byreference in their entireties.

BACKGROUND

The invention generally relates to object processing systems, andrelates in particular to robotic and other object processing systemsfor, e.g., sorting objects, for storing and retrieving objects, and forredistributing objects for a variety of purposes where the systems areintended to be used in dynamic environments requiring the systems toaccommodate the processing of a variety of objects.

Current distribution center processing systems, for example, generallyassume an inflexible sequence of operations whereby a disorganizedstream of input objects is first singulated into a single stream ofisolated objects presented one at a time to a scanner that identifiesthe object. An induction element (e.g., a conveyor, a tilt tray, ormanually movable bins) transport the objects to the desired destinationor further processing station, which may be a bin, a chute, a bag or aconveyor etc.

In certain sortation systems for example, human workers or automatedsystems typically retrieve parcels in an arrival order, and sort eachparcel or object into a collection bin based on a set of givenheuristics. For instance, all objects of like type might go to acollection bin, or all objects in a single customer order, or allobjects destined for the same shipping destination, etc. The humanworkers or automated systems might be required to receive objects and tomove each to their assigned collection bin. If the number of differenttypes of input (received) objects is large, a large number of collectionbins is required.

Such a system has inherent inefficiencies as well as inflexibilitiessince the desired goal is to match incoming objects to assignedcollection bins. Such systems may require a large number of collectionbins (and therefore a large amount of physical space, large capitalcosts, and large operating costs) in part, because sorting all objectsto all destinations at once is not clearly straightforward or efficient.

In particular, when automating sortation of objects, there are a fewmain things to consider: 1) the overall system throughput (parcelssorted per hour), 2) the number of diverts (i.e., number of discretelocations to which an object can be routed), 3) the total area ofsortation system (square feet), and 4) the annual costs to run thesystem (man-hours, electrical costs, cost of disposable components).

Current state-of-the-art sortation systems rely on human labor to someextent. Most solutions rely on a worker that is performing sortation, byscanning an object from an induction area (chute, table, etc.) andplacing the object in a staging location, conveyor, or collection bin.When a bin is full or the controlling software system decides that itneeds to be emptied, another worker empties the bin into a bag, box, orother container, and sends that container on to the next processingstep. Such a system has limits on throughput (i.e., how fast can humanworkers sort to or empty bins in this fashion) and on number of diverts(i.e., for a given bin size, only so many bins may be arranged to bewithin efficient reach of human workers).

Other partially automated sortation systems involve the use ofrecirculating conveyors and tilt trays, where the tilt trays receiveobjects by human sortation, and each tilt tray moves past a scanner.Each object is then scanned and moved to a pre-defined location assignedto the object. The tray then tilts to drop the object into the location.Further partially automated systems, such as the bomb-bay stylerecirculating conveyor, involve having doors that open on the bottom ofeach tray at the time that the tray is positioned over a predefinedchute, and the object is then dropped from the tray into the chute.Again, the objects are scanned while in the tray, which assumes that anyidentifying code is visible to the scanner.

Such partially automated systems are lacking in key areas. As noted,these conveyors have discrete trays that can be loaded with an object;they then pass through scan tunnels that scan the object and associateit with the tray in which it is riding. When the tray passes the correctbin, a trigger mechanism causes the tray to dump the object into thebin. A drawback with such systems however, is that every divert requiresan actuator, which increases the mechanical complexity and the cost perdivert can be very high.

An alternative is to use human labor to increase the number of diverts,or collection bins, available in the system. This decreases systeminstallation costs, but increases the operating costs. Multiple cellsmay then work in parallel, effectively multiplying throughput linearlywhile keeping the number of expensive automated diverts at a minimum.Such diverts do not identify a bin and cannot divert it to a particularspot, but rather they work with beam breaks or other sensors to seek toensure that indiscriminate bunches of objects get appropriatelydiverted. The lower cost of such diverts coupled with the low number ofdiverts keep the overall system divert cost low.

Unfortunately, these systems don't address the limitations to totalnumber of system bins. The system is simply diverting an equal share ofthe total objects to each parallel manual cell. Thus each parallelsortation cell must have all the same collection bins designations;otherwise an object might be delivered to a cell that does not have abin to which that object is mapped.

Automated storage and retrieval systems (AS/RS), for example, generallyinclude computer controlled systems for automatically storing (placing)and retrieving items from defined storage locations. Traditional AS/RStypically employ totes (or bins), which are the smallest unit of loadfor the system. In these systems, the totes are brought to people whopick individual items out of the totes. When a person has picked therequired number of items out of the tote, the tote is then re-inductedback into the AS/RS.

In these systems, the totes are brought to a person, and the person mayeither remove an item from the tote or add an item to the tote. The toteis then returned to the storage location. Such systems, for example, maybe used in libraries and warehouse storage facilities. The AS/RSinvolves no processing of the items in the tote, as a person processesthe objects when the tote is brought to the person. This separation ofjobs allows any automated transport system to do what it is goodat—moving totes—and the person to do what the person is betterat—picking items out of cluttered totes. It also means the person maystand in one place while the transport system brings the person totes,which increases the rate at which the person can pick goods.

There are limits however, on such conventional systems in terms of thetime and resources required to move totes toward and then away from eachperson, as well as how quickly a person can process totes in thisfashion in applications where each person may be required to process alarge number of totes. There remains a need for a more efficient andmore cost effective object sortation system that sorts objects of avariety of sizes and weights into appropriate collection bins or traysof fixed sizes, yet is efficient in handling objects of such varyingsizes and weights.

SUMMARY

In accordance with an embodiment, the invention provides a maintenancesystem for assisting in maintaining an automated carrier system formoving objects to be processed. The maintenance system includes aplurality of automated carriers that are adapted to move on an array ofdiscontinuous standard track sections, each said automated carrierincluding a carrier body that is no larger in either a length or widthdirection that a standard track section, and an automated maintenancecarrier that is adapted to move on the array of discontinuous tracksections, said automated maintenance system including a maintenance bodythat is larger in at least one of a length or width direction than thestandard track section.

In accordance with another embodiment, the invention provides amaintenance system for assisting in maintaining an automated carriersystem for moving objects to be processed. The maintenance systemincludes an automated maintenance carrier that is adapted to move on anarray of discontinuous track sections, said automated maintenancecarrier including a maintenance body that is larger in at least one of alength or width direction than the standard track section, and includesmaintenance hardware specially adapted to provide maintenance to thearray of discontinuous track sections.

In accordance with a further embodiment, the invention provides a methodof providing maintenance of an automated carrier system for movingobjects to be processed. The method includes the steps of providing aplurality of automated carriers that are adapted to move on an array ofdiscontinuous standard track sections, each said automated carrierincluding a carrier body that is no larger in either a length or widthdirection that a standard track section and providing an automatedmaintenance carrier that is adapted to move on the array ofdiscontinuous track sections, said automated maintenance carrierincluding a maintenance body that is larger in at least one of a lengthor width direction than the standard track section.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description may be further understood with reference tothe accompanying drawings in which:

FIG. 1 shows an illustrative diagrammatic view of a system in accordancewith an embodiment of the present invention;

FIG. 2 shows an illustrative diagrammatic view of the bin on the carrierin the system of FIG. 1 ;

FIG. 3 shows an illustrative diagrammatic view of a track unit in thesystem of FIG. 1 ;

FIG. 4 shows an illustrative diagrammatic view of the bin and carrier ofFIG. 2 ;

FIGS. 5A and 5B show illustrative diagrammatic views of the carrier ofFIG. 1 with wheel units rotated in each of two different directions;

FIGS. 6A and 6B shows illustrative diagrammatic views of the carrier ofFIGS. 5A and 5B, taken along lines 6A-6A and 6B-6B thereof respectively;

FIGS. 7A and 7B show illustrative diagrammatic side views of the carrierof FIG. 1 with the wheel units rotated in each of two differentdirections;

FIGS. 8A and 8B show illustrative diagrammatic bottom views of thecarrier of FIG. 1 with the wheel units rotated in each of two differentdirections;

FIGS. 9A and 9B show illustrative diagrammatic views of a pair of wheelunits of the carrier of FIG. 1 with the wheel units in the pair rotatedin each of two different directions;

FIGS. 10A and 10B show illustrative diagrammatic bottom views of thecarrier of FIGS. 8A and 8B together with a track section;

FIGS. 11A-11C show illustrative diagrammatic views of a carrierapproaching, contacting and engaging a track section in accordance withan embodiment of the present invention;

FIG. 12 shows an illustrative diagrammatic enlarged view of a wheel inthe carrier of FIG. 11C;

FIG. 13 shows an illustrative diagrammatic top view of the carrier ofFIG. 1 ;

FIG. 14 shows an illustrative diagrammatic view of the carrier of FIG. 1together with a rack on which a bin may be held;

FIG. 15 shows an illustrative diagrammatic tip view of the carrier andrack of FIG. 14 ;

FIG. 16 shows an illustrative diagrammatic side view of the carrier andrack of FIG. 14 ;

FIGS. 17A and 17B show illustrative diagrammatic side views of thecarrier and rack of FIG. 14 with the bin being placed onto the rack(FIG. 17A) and being removed from the rack (FIG. 17B);

FIG. 18 shows an illustrative diagrammatic top view of a system inaccordance with a further embodiment of the present invention thatincludes racks;

FIG. 19 shows an illustrative diagrammatic view of a rack for use inaccordance with a further embodiment of the present invention;

FIG. 20 shows an illustrative diagrammatic view of another carrier thatincludes independent wheel units in accordance with another embodimentof the present invention;

FIG. 21 shows an illustrative diagrammatic view of a track system thatincludes sensors in accordance with a further embodiment of the presentinvention;

FIG. 22 shows an illustrative diagrammatic view of a carrier inaccordance with a further embodiment of the preset invention thatprovides dual side later discharge off of the carrier;

FIG. 23 shows an illustrative diagrammatic view of a carrier inaccordance with a further embodiment of the preset invention thatprovides single side later discharge off of the carrier;

FIGS. 24A and 24B show illustrative diagrammatic views of a carrier inaccordance with a further embodiment of the present invention thatincludes a central drop mechanism;

FIG. 25 shows an illustrative diagrammatic view of a carrier inaccordance with a further embodiment of the invention that providesvacuum of a track section;

FIG. 26 shows an illustrative diagrammatic bottom view of the carrier ofFIG. 25 ;

FIGS. 27A and 27B show illustrative diagrammatic views of a doublecarrier in accordance with another embodiment of the present inventionwith the wheels in a first position (FIG. 27A) and a second position(FIG. 27B);

FIG. 28 shows an illustrative diagrammatic view of the double carrier ofFIGS. 27A and 27B that includes an object retrieval unit;

FIGS. 29A-29C show illustrative diagrammatic views of the double carrierof FIGS. 27A and 27B that includes a carrier retrieval unit (FIG. 29A),engaging another carrier (FIG. 29B), and retrieving the carrier (FIG.29C);

FIG. 30 shows an illustrative diagrammatic view of a triple carrier inaccordance with another embodiment of the present invention with thewheels in a first position;

FIG. 31 shows an illustrative diagrammatic view of the triple carrier ofFIG. 30 that includes a human personnel carrier;

FIG. 32 shows an illustrative diagrammatic view of a quad carrier inaccordance with a further embodiment of the present invention;

FIG. 33 shows an illustrative diagrammatic view of an automatedprocessing station for use in a system in accordance with an embodimentof the present invention;

FIG. 34 shows an illustrative diagrammatic view of a manual processingstation for use in a system in accordance with an embodiment of thepresent invention;

FIG. 35 shows an illustrative diagrammatic view of another bin on acarrier in accordance with another embodiment of the present invention;

FIG. 36 shows an illustrative diagrammatic view of a bin that includes awindow in accordance with a further embodiment of the present invention;

FIG. 37 shows an illustrative diagrammatic view of a bin that isprovided on a bin tray on a carrier in accordance with a furtherembodiment of the present invention;

FIG. 38 shows an illustrative diagrammatic view of a bin infeed/outfeedsystem in accordance with another embodiment of the present invention;

FIG. 39 shows an illustrative diagrammatic view of another bininfeed/outfeed system in accordance with a further embodiment of thepresent invention that includes intermediate belts;

FIG. 40 shows an illustrative diagrammatic end view of the bininfeed/outfeed system if FIG. 39 ;

FIGS. 41A-41E show illustrative diagrammatic views of stages of a binbeing fed into an object processing system using the bin infeed/outfeedsystem of FIG. 39 ;

FIGS. 42A-42D show illustrative diagrammatic views of stages of a binbeing removed from an object processing system using the bininfeed/outfeed system of FIG. 39 ;

FIG. 43 shows an illustrative diagrammatic view of a further carrier inaccordance a further embodiment of the present invention;

FIGS. 44A-44E show illustrative diagrammatic views of stages of thecarrier of FIG. 43 activating bin management mechanisms;

FIGS. 45A and 45B show illustrative diagrammatic views of the carrier ofFIG. 43 and a bin with the wheels in a first position (FIG. 45A) androtated (FIG. 45B);

FIGS. 46A and 46B show illustrative diagrammatic underside side views ofthe carrier of FIG. 43 with the wheels in a first position (FIG. 46A)and rotated (FIG. 46B);

FIGS. 47A and 47B show illustrative diagrammatic views of a wheel unitof the carrier of FIG. 43 with the wheels in a first position (FIG. 47A)and rotated (FIG. 47B);

FIGS. 48A and 48B show illustrative diagrammatic views of the undersideof the carrier of FIG. 43 with the wheels in a first position (FIG. 48A)and rotated (FIG. 48B);

FIGS. 49A-49D show illustrative diagrammatic views of stages of a binbeing fed into an object processing system using the bin infeed/outfeedsystem using a carrier of FIG. 43 ;

FIGS. 50A-50D show illustrative diagrammatic views of stages of a binbeing retrieved from an object processing system using the bininfeed/outfeed system using a carrier of FIG. 43 ;

FIG. 51 shows an illustrative diagrammatic view of a multi-processingstage system in accordance with an embodiment of the present inventionthat involves a flow process direction for bins; and

FIG. 52 shows an illustrative diagrammatic view of a multi-processingstage system in accordance with a further embodiment of the presentinvention that demonstrates the scalable nature of the system.

The drawings are shown for illustrative purposes only.

DETAILED DESCRIPTION

The invention generally relates in certain embodiments to objectprocessing systems in which objects are carried in initial bins (ortotes) in a preprocessed state and are carried in processed bins (orboxes) in a post-processed state by a variety of carriers that are ableto move about a common track system. In certain embodiments, the tracksystem includes discontinuous tiles, and the carriers include two setsof wheels that are able to pivot (together with each wheel's motor)about 90 degrees to provide movement in two orthogonal directions andwithout rotating the carrier. As herein used, the term bin includesinitial bins (including preprocessed objects), processed bins (includingpost-processed objects), empty bins, boxes, totes and/or even objectsthemselves that are large enough to be carried by one or more carriers.

FIG. 1 shows a system 10 that is formed of multiple track modules (onetrack module is shown in FIG. 3 ), and each track module includes aplurality of track sections 12. The system also includes one or moremobile carrier units 14 that carry a bin 16 as shown in FIGS. 1 and 2 ,where the carrier unit 14 rides on the track sections 12. Each tracksection 12 is generally in the form of a raised square with roundededges, and the track segments 12 are generally closely spaced from eachother (e.g., within a length or width of a mobile carrier unit 14). Withreference to FIG. 2 , each mobile carrier unit 14 may include supportfeatures for supporting a bin 16 that may contain objects 18 to beprocessed or that have been processed. A computer processor 8 maycontrol the movement of each carrier unit 14 by wireless communication,as well as all system operations as discussed further below. The tracksections 12 may also include sensors (as discussed further below) fordetecting when each carrier unit 14 is positioned about each individualtrack section 12.

FIG. 3 shows a track module 22 that includes multiple track sections 12on a frame 23 such that when multiple frames are joined together, thespacing of the adjacent track sections 12 is consistent throughout thelarger array. Each module 22 includes two sides with protrudingconnection edges 25, 27, and two sides with (only one is shown)connection recesses 29 for receiving the connection edges of adjacentmodules. One or the other to the protruding edges 25, 27 and therecesses 29, 31 may be magnetic to secure the connection betweenadjacent modules.

With reference to FIG. 4 , each mobile carrier unit 14 includes a pairof guide rails 20 that contain the bin 16, as well as a raised region 22that raises the bin sufficient for there to be room on either side ofthe raised region for shelf forks to engage the bin as will be furtherdiscussed below. Each carrier unit 14 also includes four wheelassemblies 24 that each include guides 26 for following the tracksections. Each of the wheel assemblies is pivotally mounted such thateach wheel assembly may pivot 90 degrees as generally shown at A in FIG.4 and is further discussed below. Each carrier unit 14 also includes apair of paddles 28 on either end of the unit 14. Each paddle may beturned either upward to contain a bin on the unit 14, or turned downwardto permit a bin to be loaded onto or removed from the unit 14 as willalso be discussed in more detail below.

In accordance with certain embodiments therefore, the invention providesa plurality of mobile carriers that may include swivel mounted wheelsthat rotate ninety degrees to cause each mobile carrier to move forwardand backward, or to move side to side. When placed on a grid, suchmobile carriers may be actuated to move to all points on the grid. FIGS.5A and 5B, for example, show a mobile carrier 30 that includes wheels32, 34, 36 and 38 (shown in FIGS. 9A and 9B). Each of the wheels ismounted on a motor 33, 35, 37, 39 (as best shown in FIG. 9B), and thewheel and motor units are pivotally mounted to the carrier 30 asdiscussed in more detail below. The wheel assemblies (each including awheel, its motor and guide rollers 40) are shown in one position in FIG.5A, and are shown in a second pivoted position in FIG. 5B. FIG. 6A showsan end view of the carrier 30 taken along lines 6A-6A of FIG. 5A, andFIG. 6B shows an end view of the carrier 30 taken along lines 6B-6B ofFIG. 5B. Similarly, FIG. 7A shows a side view of the carrier 30 takenalong lines 7A-7A of FIG. 5A, and FIG. 7B shows a side view of thecarrier 30 taken along lines 7B-7B of FIG. 5B.

Each carrier 30 also includes a pair of opposing rails 42, 44 forretaining a bin, as well as a raised center portion 46 and stands 43, 45on which a bin may rest. A pair of independently actuated paddles 48, 50are also provided. Each paddle 48, 50 may be rotated upward (as shown atB in FIG. 6A) to retain a bin on the carrier, or may be rotated downwardto permit a bin to be moved onto or off of a carrier. The paddles 48, 50are shown rotated downward in FIGS. 5A-7B.

Note that the orientation of the carrier 30 (also a bin on the carrier)does not change when the carrier changes direction. Again, a bin may beprovided on the top side of the carrier, and may be contained by binrails 42, 44 on the sides, as well as actuable paddles 48, 50. As willbe discussed in further detail below, each paddle 48, 50 may be rotated180 degrees to either urge a bin onto or off of a shelf, or (if both areactuated) to retain a bin on the carrier during transport. Each paddlemay therefore be used in concert with movement of the carrier to controlmovement of the bin with respect to the carrier 30. For example, when apaddle is flipped into an upward position, it may be used to urge thebin onto a shelf or rack while the carrier is moving toward the shelf orrack. Each carrier may also include one or more emergency stop switches52 for a person to use to stop the movement of a carrier in anemergency, as well as handles 54 to enable a person to lift the carrierif needed. FIG. 13 shows a top view of the carrier 30.

FIG. 8A shows a bottom view of the carrier 30 with the wheels in theposition as shown in FIG. 5A, and FIG. 8B shows a bottom view of thecarrier 30 with the wheels in the position as shown in FIG. 5B. FIGS. 8Aand 8B show all of the wheels 32, 34, 36 and 38, and each of the motors33, 35, 37 and 39 is also shown in FIG. 8B. As may be seen in FIGS. 8Aand 8B, the entire wheel assemblies including the wheel, guide rollersand the wheel motor, each pivot as a unit. With reference to FIGS. 9Aand 9B, each pair of wheel assemblies may, in an embodiment, be pivotedby a common pivot motor 56 that is coupled to the wheel assemblies vialinkages 58. In further embodiments, each wheel assembly may be pivotedby individual motors, or the pivoting wheel may be provided in a passivejoint and pivoted by the driving actions of the individual wheel motors.FIG. 9A shows a pair of wheel assemblies in a position as shown in FIG.5A, and FIG. 9B shows the pair of wheel assemblies in a position asshown in FIG. 5B. The wheel assemblies are designed to be able to pivotthe wheels around corners of a track section when the carrier isdirectly above a track section. FIGS. 10A and 10B show views similar tothe underside views of FIGS. 8A and 8B but with a track section 12superimposed on the Figures to show the relation of the wheel positionsto the track section. Note that the wheels pivot around each of thecorners of the track section. When the carrier is centered over thetrack section, therefore, the wheels may be pivoted such that thecarrier may move in a direction that is orthogonal to a prior directionwithout requiring that the carrier itself be turned. The orientation ofthe carrier is therefore maintained constant while the carrier is movedabout an array of tracks sections.

The movement of the carrier 30 about an array of track sections isfurther discussed below with regard to FIGS. 11A-11C. In short as acarrier leaves one track section, it travels toward an adjacent tracksection, and if at all misaligned, will realign itself. The realignmentof the guide rollers and the tracks may function as follows. While thetwo sets of wheels (32, 34 and 36, 38) may be designed to move thecarrier 30 in a linear direction only, some variations may occur. Thetracks 12 are positioned, though intermittently, close enough to eachother than when a carrier leaves one track and moves toward another 12(as shown at C), its potential variation off course will be small enoughthat the rounded corners of the next adjacent track will urge thecarrier back on course. Each track section may be rectangular in shape(e.g., may be square). For example, FIG. 11A shows a carrier 30 leavinga track and beginning to approach a next track 12 as the carrier movesin a direction as indicated at C. As shown in FIG. 11B, if the alignmentof the carrier 30 is off (possibly from variations in the wheels or themounting of the wheels, the placement of the track sections or any othervariable), one of the rounded corners 60 of next adjacent track 12 willbecome engaged by an on-coming guide roller 40, and the rounded corner60 will cause the carrier 30 to move slightly in a direction (as shownat D) perpendicular to the direction C to correct the direction ofmovement of the carrier 30. If the misalignment is too far off, thecarrier may reverse direction and try to become again aligned, or maystop moving and be rescued as discussed below in connection with FIG. 30. If a carrier does stop moving, the directions of movement of the othercarriers are programmed to avoid the area of the stopped carrier untilit is removed. If an area results in a number of stopped carriers overtime, the alignment of the track(s) in the area may be examined and/orreplaced.

FIG. 11C shows the carrier 30 moving in a direction C as properlyrealigned by the track 12. FIG. 12 shows a close up view of the wheel 34moving in a direction as shown at E to cause the carrier to move in thedirection C, and further shows that the guide rollers 40 roll againstthe track 12 in directions as shown at F. The guide rollers 40 do nottouch the ground (as does the wheel 34), but simply guide the directionof the carrier 30 by being urged against the track 12. In furtherembodiments, biasing means such as springs, elastics or pneumatics maybe used to urge the guide rollers against the track, and in furtherembodiments, the tracks may be more triangular shaped at the edges tofurther facilitate reception of the carriers. If too much correction isrequired, however, the system may be operating inefficiently.

Systems of the invention therefore provide for traversing the automatedcarrier in any one of four directions aligned with the track grid,allowing bidirectional column and row travel on the grid. One pivotmotor may be used for each pair of wheels, with a linkage to pivot thewheel modules. In other embodiments, one pivot motor and linkage couldbe used for all four wheels, or each wheel may have an independent pivotactuator. The system allows the wheels to follow rectangular (e.g.,square) track sections by pivoting around rounded corners of the tracksections. The system does not require differential drive line/trajectoryfollowing, and keeps the orientation of the carrier fixed throughout alloperations.

FIG. 13 shows a top view of the carrier 30, wherein each of the supportsurfaces 43, 45, 46 is shown, and FIG. 14 shows the carrier 30 with abin 16 on the carrier 30 with one paddle 48 (shown in FIG. 17B) rotatedupward to retain the bin 16 on the carrier 30 as the bin is removed froma shelf.

The tote shelf and retrieval mechanism provides that totes or boxes arecarried by a carrier, which has a tote storage area which consists of acenter rail, two side rails, and a motorized paddle on the front andback of the tote. Totes or boxes are carried by a robot, which has atote storage area that consists of a center rail, two side rails, and amotorized paddle on the front and back of the tote. In accordance withfurther embodiments, other guide and retention mechanisms may beemployed that accommodate variable sized totes or bins. When the tote isbeing driven around, both paddles are up and the tote is fullycontained. To store a tote, the robot drives into a tote rack, whichconsists of two fork tine with an incline on the front, and the inclineurges the tote above the rail height on the robot. The paddles are putdown, and the robot can drive away with the tote left behind on therack. To retrieve a tote, the robot drives under the shelf, puts itspaddles up, and drives away.

FIG. 17A shows the carrier 30 with the paddle 50 up such that the bin 16on the carrier 30 may be moved (as shown at G) onto a fixed rack 70 thatincludes two forks 72, 74. In particular, the forks 72, 74 have rampedends that engage the carrier 30 between the underside of the bin 16 andon either side of the raised center portion 46 as shown in FIGS. 15 and16 . To remove the bin 16 from the rack 70, the carrier 30 is drivenunder the rack, and the opposite paddle 48 is actuated as shown in FIG.17B. When the carrier is moved away from the rack (as shown at II), thepaddle 48 urges the bin 16 onto the carrier 30 as the carrier is drivenaway from the rack.

FIG. 17B, for example, shows the carrier 30 with the paddle 48 activatedsuch that as the carrier 30 is moved away from the rack 70 (as shown atH), the paddle 48 urges the bin 16 onto the carrier 30. Again, FIG. 17Ashows a side view of the carrier 30 with the paddle 50 engaged to urgethe bin 16 onto the rack 70, and FIG. 17B shows a side view of thecarrier 30 with the paddle 48 engaged to urge the bin 16 off of the rack70.

As mentioned above, the track system may be formed of disconnected tracksections 12. In particular, FIG. 18 shows a portion of a track system 80that includes a plurality of track sections 12, as well as racks 82, 84,86. The guide rollers discussed above are positioned to roll against theoutside of the tracks 12, and since the carriers generally travel instraight lines (either forward—backward or side—to side), the guiderollers are designed to engage the intermittent tracks and realignthemselves due to each track having slightly rounded corners. Eachintermittent track also includes a location code 88 (e.g., a QR code)that permits the carrier to register its location with the centralcontroller 8. The carrier may include a detector 76 (such as a camera ora scanner) on the underside thereof as shown in FIGS. 8A and 8B thatreads or detects each location code 88. Again, the orientation of eachcarrier does not change.

In the system 80 of FIG. 18 , numerous intermittent tracks 12 are shown,together with carriers 90, 92, 94. In particular, carrier has left a bin91 on rack 86 and has been given an instruction to move one tracksection to the North, carrier 92 carrying bin 94 has been given aninstruction to move one track section to the West, and carrier 96carrying bin 98 has been given an instruction to move one track sectionto the South. The system 80 moves each of the carriers in the tracks toavoid each other and to provide desired bins at appropriate shelves orracks. As noted, each carrier is provided an instruction to move onlyone or two track sections at a time. The system 80 is in constantcommunication with all of the carriers. In certain embodiments, thesystem provides a wireless heartbeat chain that provides a bidirectionalheartbeat between mobile carriers and fixed computing infrastructure. Ifa heartbeat isn't received by a mobile carrier, it triggers an emergencystop, and if a heartbeat isn't received by the processing system 67, ittriggers an appropriate response.

FIG. 19 shows a further embodiment of a rack unit 71 that includes atrack section 73 as its base. The rack unit 71 also includes a pair offorks 75, 77 for engaging and retaining bins. FIG. 20 shows a furtherembodiment 79 of a rack unit that includes four forks 93 that engage adifferent carrier 95 that includes three raised sections 81, 83, 85 inaddition to the rail support surfaces 87, 89. Each of the wheelassemblies 65 may also be independently pivotable (not using pivotlinkages) although the wheel assemblies are pivoted at effectively thesame time (prior to movement) as discussed above. With reference to FIG.21 , one or more of the track sections 73 may include a charging base69, having, for example, contact positive 97 and negative 99 chargeplates that may mate with charging hardware on the underside of acarrier.

FIGS. 22-32 show further embodiments of invention that are based on theabove carriers and are provided for movement about a track system asdiscussed above. For example, FIG. 22 shows a carrier 100 in accordancewith another embodiment of the present invention that includes swivelmounted wheel assemblies and is operable on a track system as discussedabove, but also includes a conveyor 102 that is mounted on the carrier100, and is actuatable to move a bin or box on the carrier in either ofopposing directions as indicated at I. When the carrier 100 is moved tobe positioned adjacent a diverting device (such as a diverting chute orconveyor as shown at 104), the carrier may actuate the conveyor 102 tomove the bin onto the diverting conveyor 104. The diverting conveyor 104may for example, but not limiting, be a belt conveyor, a rollerconveyor, a chain conveyor, a chute, another bin or a hopper. In certainembodiments, the load on the carrier 102 may be a bin that containsobjects, or may be objects themselves.

FIG. 23 shows a carrier 120 in accordance with further embodiment of thepresent invention that includes swivel mounted wheel assemblies that runalong track sections as discussed above, but also includes a tilt tray122 that is mounted on the carrier base 124, and is actuatable to move abin in a direction as indicated at J. Similarly, when the carrier 120 ismoved to be positioned adjacent a diverting device (such as a divertingconveyor as shown at 126), the carrier may actuate the tilt tray 122 tomove the bin onto the diverting conveyor 126. The diverting conveyor 126may for example, but not limiting, be a belt conveyor, a rollerconveyor, a chain conveyor, a chute, another bin or a hopper. In certainembodiments, the load on the carrier 120 may be a bin that containsobjects, or may be objects themselves.

FIGS. 24A and 24B show a carrier 130 in accordance with furtherembodiment of the present invention that includes swivel mounted wheelassemblies that run along track sections as discussed above, and alsoincludes a bomb bay drop mechanism 132 that is part of the carrier base134, and is actuatable to drop an object in a direction as indicated atK into a diverting device. When the carrier 130 is moved therefore, tobe positioned over a diverting device 136, again, such as a chute, bin,hopper, or conveyor (e.g., belt, roller chain etc.), the carrier mayactuate the drop mechanism 132 to drop the object into the divertingdevice 136.

During use, debris (e.g., dust, particles from paper or cardboard orplastic packages) may fall onto the base floor on which the tracks (ortracks sections) 12 are laid. In accordance with a further embodiment,the system provides a vacuum carrier 140 that includes the swivelmounted wheel assemblies that run along track sections as discussedabove, and also includes a vacuum assembly 142 as shown in FIG. 25 . Thevacuum assembly is mounted on the carrier chassis, and is coupled to agrid of vacuum openings 144 on the underside 146 of the carrier 140 asshown in FIG. 26 . At appropriate times, such as at the end ofprocessing session (e.g., at night), the vacuum carrier 410 may beengaged to run through the entire grid of tracks while vacuuming tocollect any debris.

Since the space between each of the tracks 382 is consistent (e.g.,consistent in an X direction and consistent in a Y direction), thecarrier may be formed not only as a single track section carrier, butmay span multiple track sections. For example, the double carrier 150shown in FIGS. 27A and 27B includes two carrier bases 152, 154, each ofwhich includes a set of four wheels that may be swiveled and run alongtrack sections as described above. The distance between the carrierbases 152, 154 is fixed as a bridge section 156 of the double carriermaintains a fixed distance between the carrier bases, and the size ofthe bridge is designed to match the spacing distance between tracksections. With further reference to FIG. 27B, when all of the wheels ofthe carrier 150 are pivoted together, the double carrier may bepermitted to be moved along the track in both X or Y dimensions.

The use of such a larger (double) carrier permits furtherfunctionalities as follows. With reference to FIG. 28 , a retrievalsystem 160 may be provided on a double carrier 161 that includes anarticulated arm 162 as well as a receiving bin 164. Any dropped objectsor debris may be picked up off of the track system and placed in the bin164. Additionally, cameras (e.g., 360 degree cameras) 166, 168 may beprovided that monitor the area around the double carrier 161 to identifyobjects that require moving to the receiving bin 164. Again, each of thetwo carrier bases of the double carrier 161 includes a set of actuatableand pivotable wheels, permitting the double carrier to be moved alongthe track in both X and Y dimensions as discussed above.

A double carrier (or larger) may also be used to pick up a disabled(single) carrier as shown in FIGS. 29A-29C. As shown in FIG. 29A, such asystem 170 may include a double carrier 171 that supports an articulatedtow arm 172 having an end effector 174, as well as a camera (e.g., a 360degree camera) 176. The system 170 also includes actuatable andpivotable wheels as discussed above, as well as a facilitation member178. In this way, the carrier 171 may move to all possible locations onthe track grid as discussed above. As shown in FIG. 29B, thefacilitation member 178 may be rotated down to provide a ramp onto thedouble carrier 171, such that a disabled carrier 180 may be grasped bythe end effector 174 (which may include an extendable section 182), anddrawn up the ramp formed by the facilitation member 178. The extendablesection 182 may be provided, for example, as a cross-sectionally arcuatemember (such as in a metal tape measure) that is stiff when (naturally)curved in the cross direction, but may be wound upon itself when causedto be flat in the cross direction. The extendable section 182 mayfurther include a central cable. As shown in FIG. 29C, once the disabledcarrier 180 is successfully drawn onto the carrier 171, the facilitationmember 178 may be partially closed (to vertical) to keep the carrier 180on the carrier 171. In this way, the double carrier 171 may be used toretrieve disabled carriers.

As shown in FIG. 30 , a triple carrier 200 may be provided that includesthree functional carrier bases 202, 204, 206, that are joined bysections 203, 205. Each of the carrier bases includes a set of fourwheels that may be pivoted and actuated to run along track sections asdescribed above. All of the wheels of the carrier 200 are swiveledtogether, permitting the carrier 200 to be moved along the track in bothX and Y directions. With reference to FIG. 31 , such a triple (or othermultiple) carrier 220 may be provided with a bed 222, head rest 224, andrails 226 for transporting human repair personnel to any point in thetrack system that is known to be in need of assistance.

Further, and as shown in FIG. 32 , a quad carrier 230 may be providedthat includes a general platform as well as four functional carrierbases 232, 234, 236 and 238 that are joined by sections of the largecommon platform. Each of the four functional carrier bases includes aset of four wheels that may be pivoted and actuated to run along tracksections as described above. All of the wheels of the quad carrier 230are pivoted together, permitting the carrier 230 to be moved along thetrack in both X and Y directions. Any of a wide variety of maintenanceof repair systems or personnel may be provided on such a quad (orgreater number) carrier.

Systems and methods of various embodiments of the invention may be usedin a wide variety of object processing systems such as sortationsystems, automated storage and retrieval systems, and distribution andredistribution systems. For example, in accordance with furtherembodiments, the invention provides systems that are capable ofautomating the outbound process of a processing system. The system mayinclude one or more automated picking stations 250 (as shown in FIG. 33) and manual picking stations 280 (as shown in FIG. 34 ) that aresupplied with containers by a fleet of mobile carriers that traverse asmart flooring structure formed of track segments as discussed above.The carriers may carry bins that can store objects. The system mayprovide a novel goods-to-picker system that uses a fleet of small mobilecarriers to carry individual inventory totes and outbound containers toand from picking stations.

In accordance with an embodiment of the system includes an automatedpicking station that picks eaches from inventory totes and loads theminto outbound containers. The system involves together machine vision,task and motion planning, control, error detection and recovery, andartificial intelligence grounded in a sensor-enabled, hardware platformto enable a real-time and robust solution for singulating items out ofcluttered containers.

With reference to FIG. 33 , the automated picking system 300 perceivesthe contents of the containers using a multi-modal perception unit anduses a robotic arm equipped with an automated programmable motiongripper and integrated software in processing system 320 to pick eachesfrom homogeneous inventory totes and place them into heterogeneousoutbound containers. These elements are co-located in a work cell thatmeets industry standard safety requirements and interfaces with tracksystem to keep the automated picking system fed with a continual supplyof inventory totes and outbound containers.

In particular, the system 300 includes an array 302 of track elements304 as discussed above, as well as automated carriers 306 that ride onthe track elements 304 as discussed above. One or more overheadperception units 308 (e.g., cameras or scanners) acquire perception dataregarding objects in bins or totes 310, as well as perception dataregarding locations of destination boxes 312. A programmable motiondevice such as a robotic system 314 picks an object from the bin or tote310, and places it in the adjacent box 312. One or both of the units310, 312 are then moved automatically back into the grid, and one or twonew such units are moved into position adjacent the robotic system.Meanwhile, the robotic system is employed to process another pair ofadjacent units (again, a bin or tote 310 and a box 312) on the otherside of the robotic system 314. The robotic system therefore processes apair of processing units on one side, then switches sides while thefirst side is being replenished. This way, the system 300 need not waitfor a new pair of object processing units to be presented to the roboticsystem. The array 302 of track elements 304 may also include shelfstations 316 at which mobile units 306 may park or pick up eitherbins/totes 310 and boxes 312. The system operates under the control, forexample, of a computer processor 320.

The manual pick station system is a goods-to-person pick stationsupplied by mobile automated movement carriers on track systems asdiscussed above. The system has the same form and function as theautomated picking station in that both are supplied by the samecarriers, both are connected to the same track system grid, and bothtransfer eaches from an inventory tote to an outbound container. Themanual system 400 (as shown in FIG. 34 ) relies on a manual team memberto perform the picking operation.

Also, the manual system raises carriers to an ergonomic height (e.g. viaramps), ensures safe access to containers on the carriers, and includesa monitor interface (HMI) to direct the team member's activities. Theidentity of the SKU and the quantity of items to pick are displayed onan HMI. The team member must scan each unit's UPC to verify the pick iscomplete using a presentation scanner or handheld barcode scanner. Onceall picks between a pair of containers are complete, the team memberpresses a button to mark completion.

In accordance with this embodiment (and/or in conjunction with a systemthat includes an AutoPick system as discussed above), a system 400 ofFIG. 34 may include an array 402 of track elements 404 that are providedon planer surfaces 406 as well as inclined surfaces 408 leading tofurther planar surfaces. The system 400 may also include visual datascreens that provide visual data to a human sorter, informing the humansorter of what goods are to be moved from totes or bins 410 todestination boxes 412. The system operates under the control, forexample, of a computer processor 420.

While the bulk of the overall system's picking throughput is expected tobe handled by automated picking systems, manual picking systems providethe carrier and track system the ability to (a) rapidly scale to meet anunplanned increase in demand; (b) handle goods that are not yet amenableto automation; and (c) serve as a QA, problem solving, or inventoryconsolidation station within the overall distribution system. The systemtherefore, provides significant scaling and trouble-shootingcapabilities in that a human sorted may be easily added to an otherwisefully automated system. As soon as a manual picking system is enabled(occupied by a sorter), the system will begin to send totes or bins 410and boxes 412 to the manual picking station. Automated picking stationsand manual picking stations are designed to occupy the same footprint,so a manual picking station may later be replaced with an automatedpicking station with minimal modifications to the rest of the system.

Again, a carrier is a small mobile robot that can interchangeably carryan inventory tote, outbound container, or a vendor case pack. Thesecarriers can remove or replace a container from or onto a storagefixture using a simple linkage mechanism. Since a carrier only carriesone container at a time, it can be smaller, lighter, and draw less powerthan a larger robot, while being much faster. Since the carriers driveon a smart tile flooring, they have lessened sensing, computation, andprecision requirements than mobile robots operating on bare floor. Thesefeatures improve cost to performance metrics.

Unlike shuttle- or crane-based goods-to-picker systems where the mobilecomponent of the system is constrained to a single aisle, all carriersrun on the same shared roadway of track sections as independentcontainer-delivery agents. The carriers can move forward, backward, leftor right to drive around each other and reach any location in thesystem. This flexibility allows the carriers to serve multiple roles inthe system by transporting (a) inventory totes to picking stations, (b)outbound containers to picking stations, (c) inventory totes to and frombulk storage, (d) full outbound containers to discharge lanes, and (e)empty outbound containers into the system. Additionally, the carriersmay be added incrementally as needed to scale with facility growth.

The track floor modules are standard-sized, modular, and connectablefloor sections. These tiles provide navigation and a standard drivingsurface for the carriers and may act as a storage area for containers.The modules are connected to robotic pick cells, induction stations frombulk storage, and discharge stations near loading docks. The moduleseliminate the need of other forms of automation, e.g. conveyors, for thetransportation of containers within the system.

FIG. 35 shows a carrier 430 in accordance with any of the abovedisclosed embodiments, wherein the bin is a cardboard box 432 for use inany shipping processes (e.g., shipping by truck), and may beparticularly designed for use by a particular site (e.g., customer) towhom the processed objects are to be sent. For example, and withreference to FIG. 36 , such a box 434 may include features (such as awindow or opening 436) through which goods may be viewed. Further, andwith reference to FIG. 37 , in further embodiments, where boxes 440 tobe used are non-standard, an adapter tray 442 may be used to accommodatefitting the non-standard box 440 to a carrier 430.

With reference to FIG. 38 , an in-feed system allows containers to beinducted into and discharged from the track system. On the inbound sideof the system, the in-feed system inducts inventory totes (IVCs) andprocessing containers (VCPs) from bulk storage and discharges depletedinventory totes back into bulk storage when they are no longer needed.On the outbound side of the system, system inducts empty containers(OBCs) and discharge sequenced containers (OBCs and VCPs) to be builtinto carts. The in-feed system may also serve as a problem solvingstation, or inventory consolidation station for containers that must beprocessed outside the overall system.

Conceptually, an in-feed station is a special module that transferscontainers between the track system and a buffer conveyor via a transfermechanism. A team member inducts a container into the system by placingthe container on the buffer conveyor located at an ergonomic height. Thebuffer conveyor conveys the container to a transfer mechanism, whichtransfers it onto a carrier. This assumes that the buffer conveyor is a20′ zero pressure accumulation MDR conveyor. This conveyor may beextended.

FIG. 38 shows an in-feed system 450 that includes a gravity conveyor 452that feeds totes 454 to a shelf 456, from which a mobile robot 458 asdiscussed above, may acquire each tote in serial fashion for movementabout a track module 460 having track sections 466 as also discussedabove. The totes may be loaded by a human that places totes of objectsonto the conveyor as shown at 462. The system operates under thecontrol, for example, of a computer processor 451.

Discharging a container proceeds in reverse: the transfer mechanismtransfers the container from the carrier to the buffer conveyor, where ateam member may remove it from the system. If a height change is needed,an inclined belt conveyor can be used to bridge the height difference.

In accordance with an embodiment the in-feed station's transfermechanisms may be provided by a serial transfer mechanism that uses alinear actuator to place containers onto and remove containers from anactuated shelf that can be accessed by carriers. The linear actuator canrun in parallel with the carrier's motion under the shelf in order toreduce cycle time. In further embodiments, the in-feed may be partiallyor fully automated using gravity fed conveyors and/or furtherprogrammable motion control systems.

The system may provide a serial transfer system in which mobile carrierson a track grid carry totes onto extendable shelves similar to thosediscussed above, except that the latch mechanism on the shelf may extendout toward a tote to retrieve a tote. The extendable shelves are incommunication with ramps, which lead to raised conveyor stations. Thesystem operates under the control, for example, of a computer processor.

To accept an inducted container, a carrier drives into a designatedmodule. While the carrier is entering the module, the actuator extends aloaded container on top of the carrier. The carrier engages its storagelatch, the transfer mechanism disengages its latch, and the actuatorretracts. Once retracted, the carrier perpendicularly exits the moduleand the next queued carrier repeats this process.

To discharge a carried container, a carrier drives into the mechanism'smodule while the actuator extends an empty shelf. The transfer mechanismengages a storage latch, the carrier disengages its storage latch, andthe transfer mechanism retracts. Once retracted, the carrierperpendicularly exits the module as described above while the containeris removed from the system by the buffer conveyor.

In accordance with further embodiments the system may include acontinuous transfer mechanism, which is a design concept that uses aseries of conveyors to match the speed of a container to a carrier, inorder to induct and discharge the container while both are in motion.

To induct a container, the carrier engages its storage latch and drivesunder the transfer mechanism at constant speed. The belted conveyoraccelerates the container and hands it off to a set of strip beltconveyors that match the speed of the carrier. The carrier receives thecontainer and secures it using its own storage latches.

To discharge a container, the carrier disengages its storage latch anddrives under the transfer mechanism at a constant speed. The containeris handed off to a set of strip belt conveyors that match the speed ofthe carrier and carry the container up a short incline to a beltedconveyor. The belted conveyor reduces the speed of the container, ifnecessary, and transfers it to the buffer conveyor.

Such a transfer system may include mobile carriers on track sectionsthat run underneath an elevated conveyor. The transfer system mayinclude a belted conveyor (for speed matching), that passes totes to apair of strip belt conveyors that urge a tote onto a carrier. The systemoperates under the control, for example, of a computer processor.

The system, therefore, accepts inventory from a bulk storage solution asinput and produces sequenced containers, amenable to being constructedinto carts, as output. The desired output of the system is specified asa collection of picking and sequencing orders that are grouped intowaves.

A picking order is a request to transfer a specified quantity of a SKUfrom an inventory tote into an outbound container. An outbound containermay contain SKUs from many different picking orders that are destinedfor similar locations in a store and have mutually compatibletransportation requirements. For example, a picking order may requesttwo packs of Body Washes, one pack of Dove Soap, and 12 other items tobe placed into an outbound container intended to replenish the soapaisle in a particular store.

A sequencing order is a request to sequentially deliver a group ofcontainers to an in-feed station to be assembled into a cart. A cart isassembled from a mixture of VCPs (for SKUs that are replenished infull-case quantity) and outbound containers (filled by picking orders)that are used to replenish nearby sort points within a store. Forexample, a sequencing order may request two other outbound containers,and five VCPs to be loaded onto a cart destined for the health & beautydepartment of a particular store.

All orders that are required to fill a trailer form a wave that must becompleted by that trailer's cut time. Each wave begins inducting thenecessary inventory containers and VCPs from bulk storage into modules.Those containers remain on modules until the wave is complete, at whichpoint they are either (i) sequenced into carts, (ii) returned to bulkstorage, or (iii) retained for use in a future wave. Multiple waves areprocessed concurrently and seamlessly: one wave may be inductinginventory while two waves are processing picking orders and a forth waveis being sequenced.

The operation for inducting inventory into the system, fulfillingpicking orders, and sequencing output, may further include thefollowing. Inventory is inducted into the system at in-feed stationsbordering the external bulk storage solution. Items intended to gothrough the each-based process must be decanted and de-trashed intoinventory containers that contain homogeneous eaches before being loadedinto the system. VCPs intended to pass through the system must be eithercompatible with carrier transport or placed in a compatible container,e.g. a tray.

Each in-feed station is manned by a team member who accepts containersfrom the bulk storage solution and transfers them onto a short length ofconveyor external to the system. Carriers dock with the station, acceptone container each, and depart to store their container in the trackgrid. The container is scanned during induction to determine itsidentity, which is used to identify its contents and track its locationwithin the module system.

Once all picking orders that require an inventory container arecomplete—and no upcoming waves are projected to require it—the containeris discharged from the system by completing the induction process inreverse. A carrier docks with the station, deposits its container, and ateam member returns the containers to bulk storage.

This same induction process is used to induct empty outbound containersinto the system using the in-feed station located near the trailerdocks. Just as with inventory containers, empty outbound containers areinducted into the system throughout the day only as they are needed toprocess active waves. Inventory containers, VCPs, and outboundcontainers are largely interchangeable: the same carriers, in-feedstations, and track modules are used to handle all three types ofcontainers.

Picking orders are processed by automated picking stations and manualpicking stations. Each picking order is completed by requesting twocarries to meet at a pick station: one carrying an inventory containerof the requested SKU and the second carrying the desired outboundcontainer. Once both carriers arrive the picking station transfers therequested quantity of eaches from the inventory container to theoutbound container. At this point, the carriers may carry the containersback into storage or to their next destination.

The system scheduling software optimizes the assignment of storagelocations sequence of orders, scheduling of arrival times, and queuingof carriers to keep pick stations fully utilized, and to optimizescheduling and usage of the grid so as to avoid traffic jams andcollisions. Orders that are not amenable to automated handling areassigned to manual picking station. Inventory and outbound containersare stored near the picking stations that are assigned to process thoseorders. When possible, multiple orders that require the same containerare collated to minimize the storage and retrieval operations.

Once all containers required to build a cart are available, i.e. therequisite VCPs have been inducted and picking orders are completed,those containers are eligible to be sequenced. Containers are sequencedby requesting carriers to transport containers from their currentlocation to an in-feed station that borders the trailer docks. Allcontainers for the cart are delivered to the same in-feed as a group,i.e. all containers assigned to one cart are discharged before anycontainers for a different cart.

Team members at the in-feed station accept the containers delivered bycarriers, assemble carts, and load completed carts onto the appropriatetrailers. The carriers and personnel may interact with an in-feedstation as discussed above.

In accordance with a further embodiment, the invention provides a feedstation 500 as shown in FIG. 39 that may feed containers to and from atrack system. The feed station 500 includes a support frame 502 thatsupports at least one conveyor for ferrying containers to and from atrack. In particular, the embodiment of FIG. 39 includes two pairs ofconveyors 504, 506 that are bi-directionally driven by a motor 508. Theframe 502 provides enough clearance on the underside thereof from frontto back, that a mobile carrier 510 may travel underneath the frame 502as shown in FIG. 40 .

For example, FIGS. 41A-41E show a tote 512 traveling along a conveyor514 above a track system that includes track sections 516 as discussedabove. As the tote 512 is moving, a mobile carrier 510 moves underneaththe conveyor 514 and matches the speed of movement of the tote 512 onthe conveyor 514 in an inbound direction. As the tote (and the mobilecarrier 510) approach the feed station 500, the motor 508 causes thestrip belts 504, 506 to move in the direction of movement of theconveyor 514 and to match the speed of the conveyor 514 (FIG. 41B).Paddles 522 on the mobile carrier 510 are flipped up and the mobilecarrier 510 moves under the tote 512 as it descends along the drivenbelts 504, 506 at the same speed as the mobile carrier 510 (FIG. 41C).The tote 512 engages the mobile carrier 510 (FIG. 41D), and is thenfully transferred to the mobile carrier 510 (FIG. 41E). As shown in FIG.41E, another tote 524 may then be provided on the conveyor 514, andanother mobile carrier 526 may be driven to similarly engage the tote524 as discussed above. The track section 518 underneath the feedstation 500 may be provided as an extended (e.g., double) track sectionto assist in maintaining alignment of the mobile carrier 510 on thetrack system during transfer of a tote.

With reference to FIGS. 42A-42D, a tote 530 may be transferred from amobile carrier 532 at the feed station 500 by providing that the motor508 drives the strip belts 504, 506 at the same speed as that of themobile carrier 532. With its rear paddle 534 engaged, the tote 530 onthe mobile carrier 532 engages the belts 506 (FIG. 42B). The tote 530 iscarried upward by the belts 506, 504 (FIG. 42C), and is provided to theconveyor 514 which carries the tote in an outbound direction (FIG. 42D).

FIG. 43 shows a carrier 600 in accordance with a further embodiment ofthe present invention. The carrier 600 includes support surfaces 602 onwhich a bin may be supported, as well as actuatable centering plates610, 612 that may be actuated to move toward (and away from) a center ofthe carrier 600 to secure a tote on the support surfaces 602. Thecarrier 600 may also include bar paddles 648, 650 on either end of thecarrier 600 that may be used similar to paddles 48, 50 as discussedabove to urge a tote onto or off of the carrier 600. The carrier 600 mayfurther include emergency stop buttons 652 that may be actuated by humanpersonnel during use. Once a carrier has been stopped, the computersystem will know to route other carriers around the stopped carrier.

FIGS. 44A-44E show the carrier 600 without wheel coverings 604. Asshown, the carrier 600 includes guide rollers 640 similar to the guiderollers 40 of the carrier 30 discussed above that are able to ride alonga discontinuous track system. The carrier 600 further includes a set ofwheels 632, 634, 636 and 638 (each of which is shown in FIGS. 48A and48B). The wheels may each be actuated by motors (e.g., wheel 634 isactuated by motor 635, and wheel 636 is actuated by motor 641) via gearsystems 629 (as shown further in FIG. 49B).

As further shown in FIGS. 44B and 44C, the bar paddles 648, 650 may beindependently actuatable to be raised, and subsequently moved toward oraway from each other. In particular, FIG. 44B shows bar paddle 650raised, and FIG. 44C shows bar paddle 44C also raised. The bar paddlesmay be actuated by a linear actuator (e.g., a threaded actuator, apneumatic actuator or an electromagnetic actuator) with a linear cam toraise the bar paddles, and the centering plates may also be actuated bya linear actuator (e.g., a threaded actuator, a pneumatic actuator or anelectromagnetic actuator). FIG. 44D shows the centering plates 610, 612being actuated to embrace a bin (or tote), and FIG. 44E shows the raisedbar paddles 648, 650 being brought toward each other to also embrace abin (or tote).

FIGS. 45A and 45B show the carrier 600 with a bin 654 on the carrier.FIG. 45A shows the wheels 632, 634, 636, 638 in a first position,aligned in a direction of the bar paddles 648, 650, and FIG. 45B showsthe wheels 632, 634, 636, 638 pivoted to a second position, aligned in adirection of the centering plates 610, 612. FIG. 46A shows a lower sideview of the carrier as shown in FIG. 44D, and FIG. 46B shows a lowerside view of the carrier as shown in FIG. 44E.

As may be seen in FIG. 46B (and with further reference to FIGS. 47A and47B), each wheel (e.g., 632) may be part of a wheel assembly 631 thatincludes a wheel motor (e.g., 633), a limited rotation gear 637, and apivot motor 638 that reciprocally drives the limited rotation gear 637via one or more drive gears 639. FIG. 47A shows the wheel 632 in a firstposition, and FIG. 47B shows the wheel 632 in a second pivoted position.Although each pivot assembly may be individually actuated, in thisembodiment, the wheels are pivoted at the same time. FIGS. 48A and 48Bshow the underside of the carrier 600 (with the wheel cover 604 on thecarrier). FIG. 48A shows the wheels 632, 634, 636, 638 in a firstposition, and FIG. 48B shows the wheels 632, 634, 636, 638 in a secondpivoted position.

FIGS. 49A-49D show a bin 654 traveling along a conveyor 664 above atrack system that includes track sections 666 as discussed above. As thebin 654 is moving, a mobile carrier 600 moves underneath the conveyor664 and matches the speed of movement of the bin 654 on the conveyor 664in an inbound direction. As the bin (and the mobile carrier 600)approach the feed station 656, the motor 658 causes the strip belts 674,676 to move in the direction of movement of the conveyor 664 and tomatch the speed of the conveyor 664 (FIG. 49B). Paddle 650 on the mobilecarrier 600 is flipped up and the mobile carrier 600 moves under the bin654 as it descends along the driven belts 674, 676 at the same speed asthe mobile carrier 600 (FIG. 49C). The bin 654 engages the mobilecarrier 600 (FIG. 49D), and is then fully transferred to the mobilecarrier 600. The track section 678 underneath the feed station 656 maybe provided as an extended (e.g., double) track section to assist inmaintaining alignment of the mobile carrier 600 on the track systemduring transfer of a bin.

With reference to FIGS. 50A-50D, a bin 654 may be transferred from amobile carrier 600 at the feed station 656 by providing that the motor658 drives the strip belts 674, 676 at the same speed as that of themobile carrier 600. With its rear paddle 648 engaged, the bin 654 on themobile carrier 600 engages the belts 506 (FIG. 50B). The bin 654 iscarried upward by the belts 676, 674 (FIG. 50C), and is provided to theconveyor 664 which carries the bin in an outbound direction (FIG. 50D).As shown in FIGS. 49C and 49D, when the bin is received on the carrier600, the centering plates 610, 612 engage the carrier 600, and as shownin FIGS. 50A and 50B, when the bin is to be released to the conveyor664, the centering plates are withdrawn, permitting the bin to be liftedoff of the carrier by the belts 674, 676. Control of the system may beprovided (e.g., wirelessly) by one or more computer processing systems680.

Each of the carriers, tracks, racks, infeed and outfeed system of theabove disclosed embodiments may be used with each of the disclosedembodiments and further system in accordance with the invention.

FIG. 51 shows a system 700 in accordance with an embodiment of thepresent invention that includes a large connected array 702 of trackmembers as well as automated mobile carriers for transporting totesabout the array. The system also includes both automated processingstations 704 and manual processing stations, as well as at least onein-feed station 706, at least one empty outbound vessel in-feed station708 and outbound stations 710. In general, the processing begins withhaving a team member retrieve inventory totes and VCPs from bulkstorage. The inventory totes and VCPs are then loaded onto an in-feedstation, and team members build empty outbound vessels and load thenonto the in-feed as well. The automated mobile carriers move requestedoutbound vessels to and from storage, and objects are processed frominventory totes at both automated stations 704 and manual stations 706.The carriers then take the VCPs straight to staging for trailer loading,and team members load completed carts onto trailers. The system operatesunder the control, for example, of a computer processor 720.

As shown at 800 in FIG. 52 , the system may be scaled up to include amuch larger array of track modules 802, and many processing stations 804that may, for example, be any of inventory in-feed stations, emptyoutbound vessel in-feed stations, automated and manual processingstations, and outbound stations as discussed above. The system operatesunder the control, for example, of a computer processor 806.

In addition to the nominal modes of operation, the systems of theinvention are designed with consideration for the following exceptions.Picking orders that contain SKUs that are not amenable to automatedhandling, e.g. violate the weight and dimension criteria, are routed tomanual picks for manual processing. Inside the manual picks station, ateam member transfers the desired number of eaches from an inventorycontainer to an outbound container. Any VCPs that are incompatible withcarrier transport, e.g. violate the weight and dimension criteria,bypass the track system. Team members are responsible for routing thesecontainers to the appropriate trailers. The track system internallyverifies the identity of containers at several points during induction,transportation, and discharge. A container that is detected to be out ofplace, unexpectedly empty, or prematurely full is automatically flaggedas an exception. When such an exception occurs, the work managementsystem is notified of the fault and the container can be routed to anin-feed station for special processing.

Maintenance of static system components can occur while the system isonline—without impeding operation—by assigning orders to other stations.This is true for both the manual and the automated processing stations.A carrier can be serviced without impacting system operation bycommanding it to move to a track module at the periphery of the system,where it is accessible to maintenance personnel. If a carrier encountersa fault that renders it inoperable, the system maintains degradedoperation by routing other carriers around the disabled carrier untilmaintenance personnel extract the carrier for service.

The interactions between team members and the track module systemincludes four primary tasks: (1) picking an each in a manual pickingstation, (2) inducting an IVC or VCP from bulk storage through anin-feed station, (3) inducting an empty OBC through an in-feed station,(4) discharging a depleted IVC through an in-feed station, and (5)discharging sequenced OBCs and VCPs to be built into a cart.

Again, manual picking is done by a team member inside a manual pickingstation, through the following steps. Carriers arrive at the manualpicking station: one carrying and IVC and one carrying an OBC. Thecontainers' identities are scanned and verified. A display informs theteam member the identity and quantity of eaches they should transfer.The team member picks one each out of the IVC. The team member scans theeach using a presentation scanner located between the IVC and OBC. Ifthe each fails to scan, the team member scans the each using a backuphandheld scanner. The team member places the each into the OBC. The teammember repeats steps the last two steps until the desired number ofeaches have been transferred. The team member presses a button toindicate that the picks from the IVC are complete. The carriers departand the process repeats. In nominal operation, multiple carriers queueat each manual picking station to minimize the team member's downtime.Multiple pairs of carriers may be accessible to the team member at onceto further reduce downtime while interchanging containers.

Containers that are amenable to automated scanning, e.g., IVCs and OBCs,are inducted by a team member at an in-feed station through thefollowing steps. A container arrives at an in-feed station. A teammember places the container on the in-feed's conveyor. The container isconveyed past an automated scanner which identifies the container'sidentity. The container is advanced onto the transfer mechanism. Anempty carrier arrives at the in-feed station. The carrier accepts thecontainer from the transfer mechanism. The carrier departs and theprocess repeats. In nominal operation, multiple carriers queue at eachin-feed station to maximize container throughput. Multiple team membersmay simultaneously service the same conveyor if necessary to match thein-feed's throughput.

Automated scanning is expected to be used for IVC and OBC induction. VCPinduction is expected to require a manual scanning step by the teammember, since vendor labels may not consistently be located on VCPs.

Containers that require manual scanning, e.g., VCPs with vendor labels,are inducted by a team member at an in-feed station through thefollowing steps. A container arrives at an in-feed station. A teammember scans the container with a presentation scanner. If the containerfails to scan, the team member scans the container using a backuphandheld scanner. The team member places the container on the in-feedconveyor. The container is advanced onto the transfer mechanism. Anempty carrier arrives at the in-feed station. The carrier accepts thecontainer from the transfer mechanism. The carrier departs and theprocess repeats. If all containers are labeled in a way that is amenableto automated scanning, e.g. if additional labels are applied to VCPs,then all containers can be inducted through the automated proceduredescribed above. Presentation and handheld scanners are only necessaryat in-feeds that are expected to be used for VCP induction.

Containers that are discharged from the system and accepted by a teammember through the following steps. A carrier carrying a containerarrives at an in-feed station. The transfer mechanism extracts thecontainer from the carrier. The transfer mechanism transfers thecontainer to a conveyor. The container is conveyed to a team member atthe end of the conveyor. The team member removes the container from theconveyor. The team member scans the container using a facility-providedHMI as part of their normal workflow (e.g., assembling a cart orreturning an IVC to circulation). The track module system is notified ofthe scan by the work management system to confirm the successfuldischarge.

If the team member is building a cart out of VCPs and OBCs, thefacility-provided HMI will direct the team member to place the containerin the correct location on the appropriate cart. The order in whichcontainers must be discharged is encoded in the sequencing orderssubmitted by the work management system.

Problem solving, resolutions of issues, and inventory consolidationoccur at designated manual picking stations and in-feed stations byspecially-trained team members. Manual picking stations are used foroperations that require access to the contents of containers inside thesystem, e.g., verifying the content of a container in the system.In-feed stations are used for operations that require access tocontainers outside the system, removing a container from the system, orinducting a new container into the system; e.g. replacing a damagedcontainer barcode.

The concept of operations for manual picking stations and In-feedstations dedicated to these roles is identical to their nominaloperation, except that more options may be available on the station'sHMI. The facility may choose to provide additional hardware (e.g. labelprinters) for the operators of these stations as needed for theirprocesses.

Control of each of the systems discussed above may be provided by thecomputer system 8, 67, 320, 420, 451, 520, 680, 720 and 806 that is incommunication with the programmable motion devices, the carriers, andthe track modules. The computer systems also contain the knowledge(continuously updated) of the location and identity of each of thestorage bins, and contains the knowledge (also continuously updated) ofthe location and identity of each of the destination bins. The systemtherefore, directs the movement of the storage bins and the destinationbins, and retrieves objects from the storage bins, and distributes theobjects to the destination bins in accordance with an overall manifestthat dictates which objects must be provided in which destination boxesfor shipment, for example, to distribution or retail locations.

In the systems of the present invention, throughput and storage mayscale independently, and all inventory SKUs may reach all outboundcontainers. The systems are robust to failures due to redundancy, andinventory totes (storage bins) and outbound boxes (destination bins) maybe handled interchangeably.

Those skilled in the art will appreciate that numerous modifications andvariations may be made to the above disclosed embodiments withoutdeparting from the spirit and scope of the present invention.

What is claimed is:
 1. An object processing system comprising: anautomated carrier system for carrying objects in any of totes or bins orboxes, said automated carrier system including a plurality of automatedcarriers, each including a carrier body for supporting any of a tote orbin or box, and a carrier base including a plurality of wheels that aremutually spaced apart and thereby generally describing a base unit area;and a maintenance system including: a maintenance body supported by aplurality of carrier bases of the automated carrier system, each carrierbase of the maintenance system being mutually separated from each otheras coupled to the maintenance body by at least two base unit areas; andmaintenance features for assisting in maintaining the object processingsystem, said maintenance features including an automated carrierretrieval system for moving a disabled automated carrier onto themaintenance body.
 2. The object processing system as claimed in claim 1,wherein each of the plurality of automated carriers includes fourwheels.
 3. The object processing system as claimed in claim 2, whereineach of the plurality of wheels is remotely controlled to pivot betweena first position and a second position by a linkage mechanism that isrotated to move the wheels at the same time.
 4. The object processingsystem as claimed in claim 1, wherein the plurality of carrier bases ofthe maintenance system includes at least two sets of four pivotablewheels.
 5. The object processing system as claimed in claim 1, whereinthe plurality of carrier bases of the maintenance system includes atleast three sets of four pivotable wheels.
 6. The object processingsystem as claimed in claim 1, wherein the plurality of carrier bases ofthe maintenance system includes at least four sets of four pivotablewheels.
 7. The object processing system as claimed in claim 1, whereinthe automated carrier system includes a plurality of disconnected tracksections.
 8. The object processing system as claimed in claim 7, whereineach of said disconnected track sections includes identifiable indiciathat is capable of being detected by the plurality of automatedcarriers.
 9. The object processing system as claimed in claim 1, whereinthe maintenance features further include a camera.
 10. The objectprocessing system as claimed in claim 1, wherein the maintenancefeatures further include an articulated arm and a receiving bin intowhich debris from the object processing system may be placed by thearticulated arm.
 11. An object processing system comprising: anautomated carrier system for carrying objects in any of totes or bins orboxes, said automated carrier system including a plurality of automatedcarriers, each including a carrier body for supporting any of a tote orbin or box, and a carrier base including a plurality of wheels that aremutually spaced apart and thereby generally describing a base unit area;and a maintenance system including: a maintenance body supported by aplurality of carrier bases of the automated carrier system, each carrierbase of the maintenance system being mutually separated from each otheras coupled to the maintenance body by at least two base unit areas; andmaintenance features for assisting in maintaining the object processingsystem, said maintenance features including a vacuum aperture coupled toa vacuum source for providing a vacuum to an underside of themaintenance body.
 12. The object processing system as claimed in claim11, wherein each of the plurality of automated carriers includes fourwheels.
 13. The object processing system as claimed in claim 12, whereineach of the plurality of wheels is remotely controlled to pivot betweena first position and a second position by a linkage mechanism that isrotated to move the wheels at the same time.
 14. The object processingsystem as claimed in claim 11, wherein the plurality of carrier bases ofthe maintenance system includes at least two sets of four pivotablewheels.
 15. The object processing system as claimed in claim 11, whereinthe plurality of carrier bases of the maintenance system includes atleast three sets of four pivotable wheels.
 16. The object processingsystem as claimed in claim 11, wherein the plurality of carrier bases ofthe maintenance system includes at least four sets of four pivotablewheels.
 17. The object processing system as claimed in claim 11, whereinthe automated carrier system includes a plurality of disconnected tracksections.
 18. The object processing system as claimed in claim 17,wherein each of said disconnected track sections includes identifiableindicia that is capable of being detected by the plurality of automatedcarriers.
 19. The object processing system as claimed in claim 11,wherein the maintenance features further include a camera.
 20. Theobject processing system as claimed in claim 11, wherein maintenancebody includes a plurality of vacuum apertures.
 21. An object processingsystem comprising: an automated carrier system for carrying objects inany of totes or bins or boxes, said automated carrier system including aplurality of automated carriers, each including a carrier body forsupporting any of a tote or bin or box, and a carrier base including aplurality of wheels that are mutually spaced apart and thereby generallydescribing a base unit area; and a maintenance system including: amaintenance body supported by a plurality of carrier bases of theautomated carrier system, each carrier base of the maintenance systembeing mutually separated from each other as coupled to the maintenancebody by at least two base unit areas; and maintenance features forassisting in maintaining the object processing system, said maintenancefeatures including an articulated arm and a receiving tote or bin or boxinto which debris from the object processing system may be placed by thearticulated arm.
 22. The object processing system as claimed in claim21, wherein each of the plurality of automated carriers includes fourwheels.
 23. The object processing system as claimed in claim 22, whereineach of the plurality of wheels is remotely controlled to pivot betweena first position and a second position by a linkage mechanism that isrotated to move the wheels at the same time.
 24. The object processingsystem as claimed in claim 21, wherein the plurality of carrier bases ofthe maintenance system includes at least two sets of four pivotablewheels.
 25. The object processing system as claimed in claim 21, whereinthe plurality of carrier bases of the maintenance system includes atleast three sets of four pivotable wheels.
 26. The object processingsystem as claimed in claim 21, wherein the plurality of carrier bases ofthe maintenance system includes at least four sets of four pivotablewheels.
 27. The object processing system as claimed in claim 21, whereinthe automated carrier system includes a plurality of disconnected tracksections.
 28. The object processing system as claimed in claim 27,wherein each of said disconnected track sections includes identifiableindicia that is capable of being detected by the plurality of automatedcarriers.
 29. The object processing system as claimed in claim 21,wherein the maintenance features further include a camera.
 30. Theobject processing system as claimed in claim 21, wherein the maintenancefeatures includes a plurality of cameras for assisting providing imagedata in connection with movement of the articulated arm.
 31. An objectprocessing system comprising: an automated carrier system for carryingobjects in any of totes or bins or boxes, said automated carrier systemincluding a plurality of automated carriers, each including a carrierbody for supporting any of a tote or bin or box, and a carrier baseincluding a plurality of wheels that are mutually spaced apart andthereby generally describing a base unit area; and a maintenance systemincluding: a maintenance body supported by a plurality of carrier basesof the automated carrier system, each carrier base of the maintenancesystem being mutually separated from each other as coupled to themaintenance body by at least two base unit areas; and maintenancefeatures for assisting in maintaining the object processing system, saidmaintenance features including human personnel transport features forassisting in transporting human personnel on the maintenance body. 32.The object processing system as claimed in claim 31, wherein each of theplurality of automated carriers includes four wheels.
 33. The objectprocessing system as claimed in claim 32, wherein each of the pluralityof wheels is remotely controlled to pivot between a first position and asecond position by a linkage mechanism that is rotated to move thewheels at the same time.
 34. The object processing system as claimed inclaim 31, wherein the plurality of carrier bases of the maintenancesystem includes at least two sets of four pivotable wheels.
 35. Theobject processing system as claimed in claim 31, wherein the pluralityof carrier bases of the maintenance system includes at least three setsof four pivotable wheels.
 36. The object processing system as claimed inclaim 31, wherein the plurality of carrier bases of the maintenancesystem includes at least four sets of four pivotable wheels.
 37. Theobject processing system as claimed in claim 31, wherein the automatedcarrier system includes a plurality of disconnected track sections. 38.The object processing system as claimed in claim 37, wherein each ofsaid disconnected track sections includes identifiable indicia that iscapable of being detected by the plurality of automated carriers. 39.The object processing system as claimed in claim 31, wherein themaintenance features further include a camera.
 40. The object processingsystem as claimed in claim 31, wherein the human personnel transportfeatures include at least one rail.